Foreword 1
This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350XJ. For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM350XA SERVICE MANUAL LIT-11616-07-50 YFM350XE SUPPLEMENTARY SERVICE MANUAL LIT-11616-08-60 YFM350XJ SUPPLEMENTARY SERVICE MANUAL 1996 by Yamaha Motor Corporation, U.S.A. First Edition, July 1996 All rights reserved. Any reproduction or unauthorized use...
Caution Pee
When tightening the locknut, hold the adjusting bolt with a spanner so that the adjusting bolt is not turned together with the locknut. Adjust parking brake cable length by turning cable adjuster in or out. Parking brake cable length 46 50mm 1.81 1.97in After this adjustment is performed, block the rear of the machine off the ground, and spin the rear wheels to ensure there is no brake drag. If any brake drag is noticed, perform the above step again. The system has been disassembled. A brake...
Caution 1
When removing the drain plug the compression spring, oil strainer and o-ring will fall off. Take care not to lose these parts. 5. if the oil filter is replaced with oil change, remove the following parts and reinstall then. Inspect the o-ring . If it is damaged, replace it with a new one. Apply lithium soap base grease to the o-ring. Install the oil filter, o-ring and oil filter cover. Inspect the o-ring. If it is damaged, replace it with a new one.
Lubrication Diagrams
Camshaft Oil cleaner Main axle Drive axle Crankshaft Oil filter Oil pump Counter axle Out-put axle Brake hose D Clutch switch D Brake cable 4 Clutch cable Brake hose Thbrottle cable 8 Handlebar switch Left D Main switch Pass the breather pipe through the hole on the handlebar protector. E Route outside the clamp and between the wire harness and the frame pipe. 3 Route inside the throttle cable and brake hose. Ground bolt Headlight To right headlight Main switch cord Clutch switch cord Handlebar...
Front And Rear Shock Absorber Adjustment
This shock absorber contains highly pressurized nitrogen gas read and understand the following information before handling the shock absorber. The manufacture cannot be held responsible for property damage or personal injury that may result from improper handling. Do not tamper with or attempt to open the cylinder assembly. Do not subject shock absorber to an open flame or other high hear source. This may cause the unit to explode due to excessive gas pressure. Do not deform or damage the...
Drive Chain Lubrication Front And Rear Shock Absorber Adjustment
The chain should be cleaned and lubricated after every use of the machine. The chain consists of many parts which work against each other. If the chain is not maintained properly, it will wear out rapidly, therefore, form the habit of periodically servicing the chain. This service is especially necessary when riding in dusty conditions. This motorcycle has a drive chain with small rubber O-rings between the chain plates. Steam cleaning, high-pressure washes, and certain solvents can damage...
Chassis
BRAKE PAD INSPECTION Front brake pad 1. Activate the brake lever or brake pedal. Brake pad Wear indicator D almost contacts brake disc- Replace brake pad as a set. Refer to the BRAKE PAD REPLACEMENT section. Brake pads wear indicator D almost contacts disc Replace pads. Refer to the BRAKE PAD REPLACEMENT section. 1. Place the machine on a level surface. Fluid level Fluid level is under LOWER level line - Replenish. IfDOT No4is not available. No.3 can be used If DOT No.4 is not available, DOT...
Caution Hfz
Make sure that the brake does not drag after adjusting it. A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Inspect and bleed the system if necessary. Brake light switch Refer to the BRAKE LIGHT SWITCH ADJUSTMENT section. Apply rear brake...
Exploded Diagrams 1
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each disassembly section.
General Torque Specifications
This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. A Distance across flats B Outside thread...
Chapter 4 Engine Overhaul
ENGINE ENGINE OIL SEAT, HEADLIGHT UNIT AND FUEL TANK 4-1 CLUTCH CABLE EXHAUST PIPE AND MUFFLER DRIVE SELECT LEVER AND CRANKCASE VENTILATION HOSE 4-3 DRIVE CHAIN ENGINE ENGINE DECOMPRESSION CAM, CAM CHAIN SPROCKET AND CYLINDER CYLINDER AND LEFT CRANKCASE COVER AND CDI MAGNETO 4-9 CAM CHAIN AND STARTER OIL FILTER AND NEUTRAL RIGHT CRANKCASE CLUTCH PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR 4-14 OIL SHIFT SHAFT OIL PIPE BEARINGS AND OIL SEALS CRANKSHAFT ROCKER INSPECTION AND REPAIR CYLINDER VALVE...
Ignition Timing Check Compression Pressure Measurement
Timing light and inductive tachometer To the spark plug lead. Timing light and inductive tachometer To the spark plug lead. P N YM-33277-A Inductive tachometer P N YU-8036-A Ignition timing Warm up the engine and keep it at the specified speed. Visually check the stationary pointer to verify it is within the required firing range D indicated on the flywheel. Incorrect firing range- Check flywheel and or pickup assembly tightness damage . Insufficient compression pressure will result in...
Clutch Adjustmentignition Timing Check
Oil gallery plug 7 Nm 0.7 m kg ,5.1 ft - lb Clutch cable free play D Out of specification Adjust. Free play 5 10 mm 0.2 0.4 in at clutch lever end Clutch cable free play Turn the adjuster s in or out until the specified free play is obtained. Turning in Free play is increased. Turning out Free play is decreased. Engine idling speed and throttle cable free play should be adjusted properly before checking the ignition timing.
e
D Margin Thickness Limit 39.9 40.1 mm 1.571-1.579 in 33.9 - 34.1 mm 1.335-1.343 in 2.26 mm 0.09 in 2.26 mm 0.09 in 1.2-1.4 mm 0.047-0.055 in 1.2-1.4 mm 0.047 - 0.055 in 1.0-1.4 mm 0.8-1.2 mm 6.975 - 6.990 6.955-6.970 7.000-7.012 lt 7.5 mm 0. 7.000 - 7.012 lt 7.5 mm 0. 0.010-0.037 0.039 - 0.0551 in 0.0315 - 0.0472 in mm 0.2746 - 0.2752 in mm 0.2738 - 0.2744 in mm 0.2756 - 0.2761 in 295 in gt mm 0.2756 - 0.2761 in 295 in gt 0.030 - 0.057 mm 0.00118-0.1 mm 0.004 in 0.1 mm 0.004 in Valve Spring...
Cable Routing
Fuel tank breather hose lt D Fuel hose Crankcase breather hose Starter relay Starting circuit cut-off relay Neutral relay CDI unit Main fuse Battery breather hose CDI magneto lead Jl Neutral switch lead 0 Pass the air vent hose through hole on the fuel tank rubber damper. M Pass the battery breather hose through the inside of frame bracket, c Pass the battery breather hose through the guide. Pass the wire harness and starter motor lead through the holder. Fasten the wire harness, starter motor...
Crankcase Ventilation Systemfuel Line Intake Manifoldexhaust System
Crankcase ventilation hose 3 Cracks Damage- Replace. 1. Inspect Fuel hoses Cracks Damage- Replace. Gaskets Cracks Damage- Replace. Exhaust pipe gasket s D Damage- Replace. Exhaust gas leakage- Repair. 1. Start the engine and let it warm up for several minutes. Inductive tachometer to the spark plug lead . Engine idling speed Out of specification Adjust. Engine idling speed 1,450 1,550 r min Engine idling speed Adjustment steps Turn in the pilot air screw until it is lightly seated. Turn out...
Spec
Steering Knuckle amp Brake Caliper Wheel Panel amp Wheel Shaft Collar Apply locking agent LOCTITE to ring nuts threads. 1st Tighten the inside ring nut 55 Nm 5.5 rrvkg, 40 ft lb . 2nd Tighten the outside ring nut while holding the inside ring nut 190 Nm 19 nvkg, 140 ft lb . 3rd Loosen the inside ring nut while holding the outside ring nut 240 Nm 24 nrrkg, 170 ft-lb . Ignition System Ignition Timing B.T.D.C. Advanced Timing B.T.D.C. Advancer Type 10 at 1,000 r min 33 at 5,000 r min Magneto-Model...
Engine 1
The valve clearance should be adjusted when the engine is cool to the touch. The piston must be at Top Dead Center TDC on compression stroke to check or adjust the valve clearance. 5. Turn the fuel cock to the OFF D position. 6. Disconnect Fuel hose D Tappet cover lt D exhaust Turn the crankshaft counterclockwise with a wrench. Align the T mark J on the crankshaft web with the stationary pointer . Measure the valve clearance by using a feeler gauge 3 . Valve clearance Insert the feeler gauge 3...
ILLUSTRATED SYMBOLS Refer to the illustration
Illustrated symbols 0 to 0 are designed as thumb tabs to indicate the chapter's number and content. S General information Specifications 3 Periodic inspection and adjustment 5 Cooling system Carburetion Drive train Chassis D Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text. Filling fluid Lubricant Special tool Tightening Wear limit, clearance Engine speed , V, A Illustrated symbols to in the exploded diagram indicate grade of...
Gen Info
The vehicle identification number is stamped into the left side of frame. Starting serial number JY43GDW0 LC051101 The vehicle identification number is used to identify your machine and may be used to register your machine with the licensing authority in your state. The engine serial number T is stamped into the right side the engine. The first three digits of these numbers are for model identifications the remaining digits are the unit production number. Designs and specifications are subject...
Caution
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip , make sure that the sharp edged corner is positioned opposite to the thrust it receives. See the sectional view. Shaft The prepare special tools are necessary for complete and accurate tune-up and assembly. Using the correct special...
Particularly Important Information
This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer. This manual consists of chapters for...
System
A switch is newly provided on the parking brake lever on the left of the handlebar to sense the parking brake condition. The ignition unit which receives a sensed signal becomes activated as follows according to the parking brake condition. switch OFF - gt Ignition occurs normally. Parking brake is applied, switch ON Misfire occurs at 2300 r min. engine will not rev up beyond 2300 r min. Ignition timing control circuit Parking switch CDI magneto source coil and pickup coil Handlebar switch left...
Engine
Big end side clearance D Big end radial clearance E 58.95 - 59.00 i nrn 2.321 2.323 in 0.010 0.025 mm 0.0004 0.0010 in Magneto model manufacturer Pickup coil resistance color Source coil resistance color C.D.I, unit model manufacturer F3T43573 M ITS U B1S H1 459 561 Q at 20 C 68 F Red - White 270 330 C2 at 20 C 68 F Brown - Green F8T34271 MITSUBISHI Model manufacturer No lead regulated voltage Semi conductor-short circuit type SH640A-12 SHINDENGEN 14.2 15.2 V Rectifier Model manufacturer...
Notice
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machines has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use....
Foreword
This Supplementary Service Manual has been prepared to introduce new service and data for the YFM350XKC. For complete service information procedures, it is necessary to use this Supplementary Service Manual together with the following manual. YFM350XA SERVICE MANUAL LIT-11616-07-50 YFM350XE SUPPLEMENTARY SERVICE MANUAL LIT-11616-08-60 YFM350XJ SUPPLEMENTARY SERVICE MANUAL LIT-11616-10-28 YFM350XKC SUPPLEMENTARY SERVICE MANUAL 1997 by Yamaha Motor Corporation, U.S.A. First Edition, April 1997...